Solar module clamp

ABSTRACT

A solar module configured in a frame assembly with multi-configuration attachment member(s), which has locking and unlocking characteristics.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present invention is a continuation of and claims priority to U.S.patent application Ser. No. 15/960,411, filed Apr. 23, 2018, now U.S.Pat. No. 11,121,273, which is a continuation of and claims priority toU.S. application Ser. No. 14/095,953 filed Dec. 3, 2013, now U.S. Pat.No. 9,954,127, which is a non-provisional of U.S. ProvisionalApplication No. 61/733,373 filed Dec. 4, 2012, which are incorporated byreference herein for all purposes.

BACKGROUND

The present application relates generally to an attachment assembly forsolar panels. More specifically, embodiments of the present inventionprovide an attachment assembly for framing solar modules.

As the population of the world increases, industrial expansion has leadto an equally large consumption of energy. Energy often comes fromfossil fuels, including coal and oil, hydroelectric plants, nuclearsources, and others. As an example, the International Energy Agencyprojects further increases in oil consumption, with developing nationssuch as China and India accounting for most of the increase. Almostevery element of our daily lives depends, in part, on oil, which isbecoming increasingly scarce. As time further progresses, an era of“cheap” and plentiful oil is coming to an end. Accordingly, other andalternative sources of energy have been developed.

Concurrent with oil, we have also relied upon other very useful sourcesof energy such as hydroelectric, nuclear, and the like to provide ourelectricity needs. As an example, most of our conventional electricityrequirements for home and business use come from turbines run on coal orother forms of fossil fuel, nuclear power generation plants, andhydroelectric plants, as well as other forms of renewable energy. Oftentimes, home and business use of electrical power has been stable andwidespread.

Most importantly, much if not all of the useful energy found on theEarth comes from our sun. Generally all common plant life on the Earthachieves life using photosynthesis processes from sun light. Fossilfuels such as oil were also developed from biological materials derivedfrom energy associated with the sun. For human beings including “sunworshipers,” sunlight has been essential. For life on the planet Earth,the sun has been our most important energy source and fuel for modernday solar energy.

Solar energy possesses many characteristics that are very desirable!Solar energy is renewable, clean, abundant, and often widespread.Certain technologies have been developed to capture solar energy,concentrate it, store it, and convert it into other useful forms ofenergy.

Solar panels have been developed to convert sunlight into energy. As anexample, solar thermal panels often convert electromagnetic radiationfrom the sun into thermal energy for heating homes, running certainindustrial processes, or driving high grade turbines to generateelectricity. As another example, solar photovoltaic panels convertsunlight directly into electricity for a variety of applications. Solarpanels are generally composed of an array of solar cells, which areinterconnected to each other. The cells are often arranged in seriesand/or parallel groups of cells in series. Accordingly, solar panelshave great potential to benefit our nation, security, and human users.They can even diversify our energy requirements and reduce the world'sdependence on oil and other potentially detrimental sources of energy.

Although solar panels have been used successfully for certainapplications, there are still limitations. Often, solar panels are oftendifficult to assembly and maintain in the field. Cumbersome frames,attachment members, and assembly techniques are often required.Unfortunately, conventional solar tracking assembly techniques are ofteninadequate. These and other limitations are described throughout thepresent specification, and may be described in more detail below.

From the above, it is seen that techniques for improving solar systemsare highly desirable.

SUMMARY OF THE INVENTION

According to the present application, techniques related generally to anattachment assembly for solar panels are provided. More specifically,embodiments of the present invention provide an attachment assembly forframing solar modules.

In an example, the present invention provides a frame assembly includingattachment members to configure at least a pair of solar modules in anarray.

In an example, the present assembly uses a pair of rails that can beconfigured or mounted on either long or short side of an assemblydevice. In an example, the rails can be pre-mounted with the assemblydevice lock in place. In an example, the rail to the module can beaccomplished with module centerline scribe on the frame. In an example,a pair of nuts to the U-bolts is provided to be mounted during trackerinstallation. In an example, the present assembly provides for easyaccess to bolts during tightening, subsequent module attached afterbolts tightened. In an example, solar modules can be locked into placeduring installation.

In an example, the present invention provides a solar module system,e.g., tracker. The system has a first solar module comprising a firstframe structure configured with a first groove region disposed therein.The system has a second solar module comprising a second frame structureconfigured with a second groove region disposed therein. The first andsecond modules are among a plurality of modules in one or more examples.

In an example, the system has an attachment member (e.g., member withcam structure for interlocking or other attachment configuration). Theattachment member comprises a first end region having a first spatialconfiguration and a second end region having a second spatialconfiguration. The attachment member comprises a length provided betweenthe first end region and the second end region. The first end region isconfigured to integrate the first spatial region configuration with thefirst groove region by intimately coupling the first spatial region withthe first groove region by initiating the intimate coupling along afirst spatial direction relative to the first groove region. In anexample, the second end region is configured to intimately couple to thesecond groove region by initiating the intimate coupling along a secondspatial direction that is different from the first spatial direction,while the initiating of the initiating of the intimate coupling in thesecond spatial direction occurs while the first spatial region is firmlyengaged with the first groove.

Various additional objects, features and advantages of the presentinvention can be more fully appreciated with reference to the detaileddescription and accompanying drawings that follow.

BRIEF DESCRIPTION OF THE DRAWINGS

The patent or application file contains at least one drawing executed incolor. Copies of this patent or patent application publication withcolor drawing(s) will be provided by the Office upon request and paymentof the necessary fee.

FIG. 1 is a simplified perspective view of a frame assembly (includingindications for x-y-z directions) for a plurality of solar modulesaccording to an embodiment of the present invention.

FIG. 2 is a more detailed view along the x-y direction for the frameassembly including attachment member according to an embodiment of thepresent invention.

FIG. 3 is a more detailed view of an x-z direction or “top view” for theframe assembly according to an embodiment of the present invention.

FIG. 4 is an exposed perspective view of the frame assembly (includingindications for x-y-z direction) where one of the solar modules has beenremoved according to an embodiment of the present invention.

FIG. 5 is an exposed side view of the frame assembly where one of thesolar modules has been removed according to an embodiment of the presentinvention.

FIG. 6 is a simplified diagram of an attachment member and illustrationof coupling the attachment member to a solar module frame according toan embodiment of the present invention.

FIG. 7 is perspective view of clamping assembly according to analternative embodiment of the present invention.

FIG. 8 is a side view of the clamping assembly according to thealternative embodiment.

FIGS. 9 and 10 illustrate, respectively, a perspective view and atop-view of a clamp according to the alternative embodiment.

DESCRIPTION OF THE SPECIFIC EMBODIMENTS

According to the present application, techniques related generally to anattachment assembly for solar panels are provided. More specifically,embodiments of the present invention provide an attachment assembly forframing solar modules.

FIG. 1 is a simplified perspective view of a frame assembly (includingindications for x-y-z directions) for a plurality of solar modulesaccording to an embodiment of the present invention. As shown, the frameassembly includes a pair of frame rail assemblies coupled together usingan attachment member, which interlocks each of the frame rail assembliestogether with the module frames. Additionally, the frame rail assembliesinclude a pair of openings for a U-bolt and clamp or other member tocouple the rail assembly to a pipe or other member of a tracker or solarsystem. Of course, there can be other variations.

FIG. 2 is a more detailed view along the x-y direction for the frameassembly including attachment member according to an embodiment of thepresent invention. In an example as shown is a direct normal view inplane of a module glass. In an example, as shown in a center region is acam. The cam can either work for two modules, or just one ifconstruction tolerance is needed for spacing the modules along thetorque tube. Of course, there can be other variations. Further detailsof the present assembly can be found throughout the presentspecification and more particularly below.

FIG. 3 is a more detailed view of an x-z direction or “top view” for theframe assembly according to an embodiment of the present invention. Asshown, the frame assembly includes a pair of frames each of which isconfigured on an edge of a solar module. The assembly also includes apair of rails sandwiched between the frames. An attachment member, whichis configured between the rails holds the frame assembly together, asshown.

FIG. 4 is an exposed perspective view of the frame assembly (includingindications for x-y-z direction) where one of the solar modules has beenremoved according to an embodiment of the present invention. In anexample, one of the modules has been removed. In an example, an extrudedpanel rail bracket is shown, which is configured to a module frame. Thecam configured to the panel rail is also shown. In an example, the camcan either fasten to one rail or both rails. In an example, the railmounts to a U-bolt and U-bolt clamp, which are configured through therail along a direction normal to the direction of the length of therail. In an example, the cam will serve as an electrical bonding path,as well as a mechanical lock to prevent the bracket from sliding out ofthe module groove. In an example, the U-bolt clamp will be secured to asupport member (or pipe type member) of a tracker.

FIG. 5 is an exposed side view of the frame assembly where one of thesolar modules has been removed according to an embodiment of the presentinvention. As shown, the exposed side view is configured as a site for asecond solar module to couple to the pair of rail structures, which canbe separate units or integrated together, depending upon the embodiment.

In an example, the system has an attachment member (e.g., member withcam structure for interlocking or other attachment configuration). Theattachment member comprises a first end region having a first spatialconfiguration and a second end region having a second spatialconfiguration. The attachment member comprises a length provided betweenthe first end region and the second end region. The first end region isconfigured to integrate the first spatial region configuration with thefirst groove region by intimately coupling the first spatial region withthe first groove region by initiating the intimate coupling along afirst spatial direction relative to the first groove region. In anexample, the second end region is configured to intimately couple to thesecond groove region by initiating the intimate coupling along a secondspatial direction that is different from the first spatial direction,while the initiating of the initiating of the intimate coupling in thesecond spatial direction occurs while the first spatial region is firmlyengaged with the first groove.

In an example, the first spatial configuration comprises a first lockingdevice, which has a locking structure configured to operably couple tothe first groove structure in a locking position rather than an unlockedposition. In an example, the second spatial configuration comprises asecond locking device configured to operably couple to the second groovestructure in a locking position rather than an unlocked position. In anexample only, the attachment member can be similar or the same as thoseprovided by Zep Solar, Inc., although there can be others manufacturers.

In an example, the first groove region comprises a first recessed regiondisposed between a first pair of elevated regions. In an example, thesecond groove region comprises a second recessed region between a secondpair of elevated regions.

In an example, the first frame structure is configured around aperiphery of the first solar module. In an example, the second framestructure is configured around a periphery of the second solar module.

In an example, the first groove region is similar in shape and size asthe second groove region.

In an example, the first frame structure and the second frame structurecomprise, respectively, a first rail structure and a second railstructure coupled together using the attachment member.

In an example, the first rail structure and the second rail structurecomprising a pair of openings to operably couple a U-bolt and clampassembly to be configured to a support member.

In an example, the support member is provided on a tracker system.

In an example, the U-bolt and claim assembly comprises a pair ofextension members, each of the extension members having an opening, theopening being configured to allow an attachment device to be insertedthere through to couple a portion of each of the first frame structureand second frame structure together. Further details of the attachmentmember is described throughout the present specification and moreparticular below.

FIG. 6 is a simplified diagram of an attachment member and illustrationof coupling the attachment member to a solar module frame according toan embodiment of the present invention. As shown is the attachmentmember in an example, using a tongue and key side. The attachment memberis operably coupled to a rail member, which is provided for an assembly.The attachment member and rail are operably couple to a first solarmodule, which is then configured to a second solar module, as described.

FIG. 7 is perspective view of clamping assembly according to analternative embodiment of the present invention. As shown, the U-boltand clamp assembly comprises a pair of extension members integrated withthe U-bolt and clamp assembly. Each of the extension members having anopening disposed within the extension member. The opening is configuredto allow an attachment device to be inserted there through to couple aportion of each of the first frame structure and second frame structuretogether such that the clamp assembly, pair of rails, and frames form asandwich structure.

FIG. 8 is a side view of the clamping assembly according to thealternative embodiment.

FIGS. 9 and 10 illustrate, respectively, a perspective view and atop-view of a clamp according to the alternative embodiment.

It is understood that the examples and embodiments described herein arefor illustrative purposes only and that various modifications or changesin light thereof will be suggested to persons skilled in the art and areto be included within the spirit and purview of this application andscope of the appended claims. In an example, each of the elements can bemade of a suitable material such as metal, stainless steel, iron,aluminum, or alloys thereof, among others, which are sufficiently rigidand weather proof.

I claim:
 1. A solar tracker system comprising: a first solar moduleincluding a first frame structure with a first groove disposed in thefirst frame structure; a second solar module including a second framestructure with a second groove disposed in the second frame structure;and an attachment member having: a body having a length provided betweena first end region and a second end region, and including a clampassembly, wherein the clamp assembly includes a pair of planar extensionmembers, each of the pair of planar extension members having an opening,the opening configured to allow an attachment device to be insertedtherethrough to couple the body to the first and second solar modules; afirst rail coupled to a first side surface of the body and extendingalong the length of the body, the first rail configured to fit inside ofthe first groove; a second rail coupled to a second side surface of thebody opposite the first side surface and extending along the length ofthe body, the second rail configured to fit inside of the second groove;and a U-bolt having a first end portion and a second end portion,wherein the clamp assembly further includes a pair of channelsconfigured to receive the respective first and second end portions ofthe U-bolt, and a planar portion coupled between the pair of channels,wherein the U-bolt and clamp assembly are configured to receive asupport member of a solar tracker between the U-bolt and the clampassembly.
 2. The solar tracker system of claim 1, further comprising afirst locking device disposed within a first space of the first rail,the first locking device configured to operably couple the body of theattachment member to the first groove of the first solar module.
 3. Thesolar tracker system of claim 1, further comprising a second lockingdevice disposed within a second space of the second rail, the secondlocking device configured to operably couple the body of the attachmentmember to the second groove of the second solar module.
 4. The solartracker system of claim 1, wherein the first and second rails extend inparallel along the length of the body.
 5. The solar tracker system ofclaim 1, wherein the first groove comprises a first recessed regiondisposed between a first pair of elevated regions; and wherein thesecond groove comprises a second recessed region between a second pairof elevated regions.
 6. The solar tracker system of claim 1, wherein thefirst frame structure is configured around a periphery of the firstsolar module; and wherein the second frame structure is configuredaround a periphery of the second solar module.
 7. The solar trackersystem of claim 1, wherein the first groove is similar in shape and sizeas the second groove.
 8. The solar tracker system of claim 1, whereinthe clamp assembly includes a first pair of semicircular recesses formedin a middle portion of a planar-shaped material and a correspondingsecond pair of semicircular recesses formed at respective end portionsof the planar-shaped material on the same side of the planar-shapedmaterial, wherein the planar-shaped material is folded at locationsbetween the first pair of semicircular recesses and the second pair ofsemicircular recesses, respectively, such that the first pair ofsemicircular recesses and the respective second pair of semicircularrecesses form the respective pair of channels.
 9. The solar trackersystem of claim 1, wherein the opening is configured to allow anattachment device to be inserted therethrough to couple a portion ofeach of the first and second frame structures together such that theclamp assembly, the first and second rails, and the first and secondframe structures form a sandwich structure.
 10. A solar tracker systemcomprising: a first solar module including a first frame structure witha first groove disposed in the first frame structure; a second solarmodule including a second frame structure with a second groove disposedin the second frame structure; and an attachment member including: aclamp assembly having a length provided between a first end region and asecond end region, each of the first end region and the second endregion having an opening, the opening configured to allow an attachmentdevice to be inserted therethrough to couple the clamp assembly to thefirst and second solar modules; a first rail coupled to a first sidesurface of the clamp assembly and extending along the length of theclamp assembly, the first rail configured to fit inside of the firstgroove; a second rail coupled to a second side surface of the clampassembly opposite the first side surface and extending along the lengthof the clamp assembly, the second rail configured to fit inside of thesecond groove; and a U-bolt having a first end portion and a second endportion, wherein the clamp assembly further includes a pair of channelsconfigured to receive the respective first and second end portions ofthe U-bolt, and a planar portion coupled between the pair of channels,wherein the U-bolt and clamp assembly are configured to receive asupport member of a solar tracker between the U-bolt and the clampassembly.
 11. The solar tracker system of claim 10, wherein the clampassembly includes a first pair of semicircular recesses formed in amiddle portion of a planar-shaped material and a corresponding secondpair of semicircular recesses formed at respective end portions of theplanar-shaped material on the same side of the planar-shaped material,wherein the planar-shaped material is folded at locations between thefirst pair of semicircular recesses and the second pair of semicircularrecesses, respectively, such that the first pair of semicircularrecesses and the respective second pair of semicircular recesses formthe respective pair of channels.
 12. The solar tracker system of claim10, wherein the opening is configured to allow an attachment device tobe inserted therethrough to couple a portion of each of the first andsecond frame structures together such that the clamp assembly, the firstand second rails, and the first and second frame structures form asandwich structure.
 13. An attachment member for attaching at least onesolar module to a support member of a solar tracker, the attachmentmember comprising: a clamp assembly having a length provided between afirst end region and a second end region, each of the first end regionand the second end region having an opening, the opening configured toallow an attachment device to be inserted therethrough to couple theclamp assembly to the at least one solar module; a first rail coupled toa first side surface of the clamp assembly and extending along thelength of the clamp assembly, the first rail configured to fit inside ofa first groove of a first solar module; a second rail coupled to asecond side surface of the clamp assembly opposite the first sidesurface and extending along the length of the claim assembly, the secondrail configured to fit inside of a second groove of a second solarmodule; and a U-bolt having a first end portion and a second endportion, wherein the clamp assembly further includes a pair of channelsconfigured to receive the respective first and second end portions ofthe U-bolt, and a planar portion coupled between the pair of channels,wherein the U-bolt and clamp assembly are configured to receive asupport member of a solar tracker between the U-bolt and the clampassembly.
 14. The attachment member of claim 13, wherein the clampassembly includes a first pair of semicircular recesses formed in amiddle portion of a planar-shaped material and a corresponding secondpair of semicircular recesses formed at respective end portions of theplanar-shaped material on the same side of the planar-shaped material,wherein the planar-shaped material is folded at locations between thefirst pair of semicircular recesses and the second pair of semicircularrecesses, respectively, such that the first pair of semicircularrecesses and the respective second pair of semicircular recesses formthe respective pair of channels.